05-10
SECTION 26 32 13
ENGINE GENERATORS
SPEC WRITER NOTES: Use this section only
for NCA projects. Delete between //----//
if not applicable to project. Also delete
any other item or paragraph not applicable
in the section and renumber the
paragraphs.
PART 1 - GENERAL
1.1 DESCRIPTION
A. This section specifies the furnishing, complete installation, connection
and testing of the engine generator system. This includes: air
filtration, starting system, generator controls, instrumentation,
lubrication, fuel system, cooling system and exhaust system.
B. The engine generator system shall be fully automatic and shall
constitute a unified and coordinated system ready for operation.
C. The engine generator system shall include, but not be limited to the
following:
1. Diesel Engine.
2. Lubrication Oil System.
3. Fuel Oil System.
4. Cooling System.
//5.
Remote Radiator and Enclosure //.
6. Intake and Exhaust Air Systems.
7. Starting System.
8. Generator.
9. Controls, Supervision and Distribution.
//10.Outdoor Generator Enclosure.//
11.
Spare Parts.
1.2 RELATED WORK
A. Section 13 05 41, SEISMIC RESTRAINT REQUIREMENTS FOR NON-STRUCTURAL
COMPONENTS: Seismic requirements for non-structural equipment.
B. Section 26 05 11, REQUIREMENTS FOR ELECTRICAL INSTALLATIONS: General
electrical requirements and items that are common to more than one
section of Division 26.
C. Section 26 05 21, LOW-VOLTAGE ELECTRICAL POWER CONDUCTORS AND CABLES
(600 VOLTS AND BELOW: Cables and Wiring.
D. Section 26 36 23, AUTOMATIC TRANSFER SWITCHES: Requirements for
automatic transfer switches.
E. Section 26 05 26, GROUNDING AND BONDING FOR ELECTRICAL SYSTEMS:
Requirements for personnel safety and to provide a low impedance path
for possible ground fault currents.
ENGINE GENERATORS
26 32 13 - 1
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F. Section 26 24 11, DISTRIBUTION SWITCHBOARDS: Requirements for secondary
distribution switchboards.
1.3 QUALITY ASSURANCE
A. The supplier of the diesel-engine generator set shall be responsible for
satisfactory total operation of the system and its certification. This
supplier shall have had experience with three or more installations of
systems of comparable size and complexity in regards to coordinating,
engineering, testing and supervising. Each of these installations shall
have been in successful operation for three or more years. Prior to
review of submittals, the Department of Veterans Affairs reserves the
right to:
1. Have the manufacturer submit a list of locations of similar
installations.
2. Inspect any of these installations and operations of engine-generator
set, and question the user concerning the installations without the
presence of the supplier.
B. Factory authorized representative shall be capable of providing
emergency maintenance and repairs at the project site within ____ hours
maximum of notification.
C. Engine generator and auxiliary components shall be supplied from a
single manufacturer.
D. Noise level developed by the generator set shall be as herein specified.
E. Factory Test: The Government shall have the option of witnessing the
following tests at the factory. The Government will pay all expenses for
the Government representative's trip to witness these tests. Contractor
shall notify the RESIDENT ENGINEER/COTR 15 days prior to date of
testing. Manufacturer shall furnish load banks, testing instruments and
all other equipment as necessary to perform these tests.
1. Load Test: Shall include six hours of continuous operation; four
hours while the set is delivering 100 percent of the specified KW and
two hours while delivering 110 percent of the specified KW. During
this test record the following data at 20-minute intervals:
Time
Engine RPM
Oil Temperature Out
KW
Water Temperature In
Fuel Pressure
Voltage
Water Temperature Out
Oil Pressure
Amperes
Oil Temperature In
Ambient Temperature
ENGINE GENERATORS
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2. Quick Start Test: Record time required for the engine generator set
to develop specified voltage, frequency and KW load from a standstill
condition.
1.4 SUBMITTALS
A. Submit in accordance with Section 26 05 11, REQUIREMENTS FOR ELECTRICAL
INSTALLATIONS.
B. Shop Drawings:
1. Sufficient information, clearly presented, shall be included to
determine compliance with drawings and specifications.
2. Data shall be submitted in the following form:
a. Technical data sheets (TDS): These include published performance,
rating and derating curves, published ratings, catalog cuts,
pictures, manufacturer's specifications, material composition, and
gauge thickness.
b. Description of operation (DO): Manufacturer's literatures and, if
suitable, diagrams.
c. Calculations (CALC): Detailed engineering calculations with all
equations, graphs, assumptions, and approximations shown, and data
sources referenced.
d. Certification (CERT): Written confirmation as to the document's
accuracy, and genuineness.
e. Shop Drawings (SD): Scaled drawings showing plan views, side
views, elevations and cross sections.
f. Diagrams (DGM): These include control system diagrams, elementary
diagrams, control sequence diagrams or table, wiring diagrams,
interconnections diagrams (between local control cubicles, remote
annunciator panels, remote derangement panels, remote monitoring
panels, remote exercising panel, illustrative diagrams, flow
diagrams, and other like items.
3. Prior to fabrication, submit for approval the following data for each
engine-generator set, transfer device and control and supervisory
equipment:
a. Engine generator set: TDS, SD// including subtransient reactance
and short-circuit current capacity.
b. Engine jacket water heaters: TDS
c. Muffler assembly: TDS, SD
d. Motor-operated damper assembly: TDS
e. Day tank and pumps or integral sub-base fuel tank: TDS, CALC
f. Batteries, racks and charger: TDS, CALC
g. Torsional Vibration: CERT
h. Control and Supervisory Equipment: TDS, DGM, DO, SD
ENGINE GENERATORS
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i. Performance:
1) Voltage regulating equipment: TDS
2) Frequency regulating equipment: TDS
3) Voltage and frequency dips and recovery times due to specified
motor loading: CALC
4) Antifreeze derating: TDS
5) Ambient derating: TDS
SPEC WRITER NOTES: Include Items j, k, l
and m as applicable.
//j.
Remote radiator: // TDS // SD //
//k.
Fuel oil system: DGM //
//l.
Cooling system: DGM //
//m.
Vibration isolators: TDS, CALC //
//n.
Sound power level data for the packaged outdoor generator.//
//o.
Vibration isolation system performance data from no-load to
full-load. This must include seismic qualification of the enginegenerator mounting, base and vibration isolation.//
C. Manuals:
1. Submit, simultaneously with the shop drawings, companion copies of
complete maintenance and operating manuals of the engine generator
set and auxiliaries including technical data sheets, wiring diagrams,
and information, such as telephone number, fax number, and web sites,
for ordering replacement parts.
2. Two weeks prior to the final inspection, submit four copies of the
updated maintenance and operating manual to the RESIDENT
ENGINEER/COTR:
a. Include complete "As installed" diagrams, which indicate all items
of equipment and their interconnecting wiring.
b. Include complete diagrams of the internal wiring for each of the
items of equipment, including "As installed" revisions of the
diagrams.
c. The wiring diagrams shall identify the terminals to facilitate
installation, maintenance, operation and testing.
d. Complete lists of spare parts and special tools recommended for
two years of normal operation of the complete system.
D. Certifications:
1. Prior to fabrication of the engine-generator set, submit the
following for approval, to the RESIDENT ENGINEER/COTR:
a. A certification in writing that a diesel engine of the same model
and configuration, with the same bore, stroke, number of
cylinders, and equal or higher BMEP and RPM ratings as the
ENGINE GENERATORS
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proposed diesel engine has been operating satisfactorily, with
connected loads of not less than 75 percent of the specified
KW/KVA rating, for not less than 2,000 hours without any failure
of a crankshaft, camshaft, piston, valve, injector or governor
system.
b. A certification in writing that devices and circuits will be
incorporated to protect the voltage regulator and other components
of the auxiliary electrical power system during operation of the
diesel engine-generator set at speeds other than the rated RPM
while performing maintenance. Include thorough descriptions with
submittal of any precautions, which will be necessary to protect
the voltage regulator and other components of the system during
operation of the diesel engine-generator set at speeds other than
the rated RPM.
2. Prior to installation of the engine-generator set at the job site,
submit four copies of the following to the RESIDENT ENGINEER/COTR:
a. Certified test data, alternator temperature rise test and strip
chart recordings, and photographs showing test setup and
equipment.
3. Two weeks prior to the final inspection, submit four copies of the
following, to the RESIDENT ENGINEER/COTR:
a. Certified test report by the manufacturer of the engine-generator
set that the auxiliary electrical power system conforms to the
requirements of the drawings and specifications.
b. Certified report of field tests from the contractor that the
engine-generator set and major auxiliaries have been properly
installed, adjusted and tested.
SPEC WRITER NOTES: Specify seismic zone
factor "Z" value so engine-generator set
manufacturers can check/design seismic
strength of their equipment. Delete the
following paragraph if the enginegenerator set(s) is located outside the
seismic zone.
//c.
A certificate by the manufacturer that the engine-generator
set, accessories, and components will withstand the seismic forces
(Z=___) and that the set will be fully operational after the
seismic event at the project site. //
1.5 STORAGE AND HANDLING
A. Equipment shall withstand the mechanical stresses caused by rough
handling during shipment in addition to the electrical and mechanical
ENGINE GENERATORS
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//2.
Shall be capable of operating continuously for // two // six // 24
// consecutive hours within any 24-hour period of operation at 110
percent of its specified rating without damage.//
D. Assemble, connect and wire the equipment at the factory so that only the
external connections need to be made at the construction site.
E. Unit shall be factory painted with manufacturer's primer and standard
finishes.
F. Coordinate the components of the system and their arrangements,
electrically and mechanically.
G. Connections between components of the system shall conform to the
recommendations of the manufacturer of the diesel engine-generator set.
H. Couplings, shafts, and other moving parts shall be enclosed and guarded.
Guards shall be metal, ruggedly constructed, rigidly fastened and
readily removable for convenient servicing of the equipment without
disassembling any pipes and fittings.
I. Generator set and cooling system shall be furnished with extended life
antifreeze solution to protect the system from freezing at all times.
J. Generator set shall have the following features:
1. Factory-mounted on a common, rigid, welded, structural steel base.
2. The maximum engine-generator set vibration in the horizontal,
vertical, and axial directions shall be limited to 0.15mm with an
overall velocity limit of 24 mm/sec RMS, for all speeds.
3. The isolators shall be constrained with restraints capable of
withstanding static forces in any direction equal to twice the weight
of the supported equipment.
4. Automatic start, accelerate to the specified RPM and deliver the
specified KW/KVA output at 60 Hz within 10 seconds after a single
pole contact closes in a remote device.
5. Recover rapidly from instantaneous changes between no load and the
specified KW/KVA rating, and the reverse changes of load, without
damage.
6. Shall be capable of operating satisfactorily as specified for not
less than 10,000 hours between major overhauls.
7. Engine-generator set shall be statically and dynamically balanced at
the factory in order to comply with the maximum vibration velocity
specified in paragraph 3.1.D.
2.2 DIESEL ENGINE
A. Coupled directly to a generator.
B. Minimum 4-cylinders.
C. Operating speed shall be 1800 RPM.
ENGINE GENERATORS
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paralleling operations and when supplying
a UPS system.
A. Isochronous; electronic or hydraulic type.
B. Steady-state speed band at 60 Hz shall not exceed plus or minus 1/3 of
one percent.
C. At 60 Hz, when load changes equal to 25 percent of the specified KW/KVA
rating, frequency change shall not exceed two percent and it shall
recover to 60 Hz within three seconds.
D. At 60 Hz, when load changes equal to 100 percent of the specified KW/KVA
rating, frequency change shall not exceed eight percent and it shall
recover to 60 Hz within five seconds.
E. While the engine is running, manual speed adjustments may be made.
2.4 LUBRICATION OIL SYSTEM
A. Pressurized type.
B. Positive-displacement pump driven by engine crankshaft.
C. Full-flow strainer and full-flow or by-pass filters.
D. Filters shall be cleanable or replaceable type and shall remove
particles as small as 3 microns without removing the additives in the
oil. For by-pass filters, flow shall be diverted without flow
interruption.
E. Extend lube oil sump drain line passing out through the skid base and
terminate it with a drain valve and plug.
//F.
Provide a 120-volt oil heater for exterior generator set//.
2.5 FUEL OIL SYSTEM
A. Shall comply with NFPA 37 and NFPA 30, and have the following features:
1. Injection pump(s) and nozzles.
2. Plungers shall be carefully lapped for precision fit and shall not
require any packing.
3. Filters or screens, which require cleaning or replacement, will not
be permitted in the injection system assemblies.
4. Return surplus oil from the injectors to the main storage tank by
gravity or a pump.
5. Filter System:
a. Dual primary filters shall be located in the day tank.
b. Secondary filters (engine mounted) shall be located so the oil
will be thoroughly filtered before it reaches the injection system
assemblies.
c. Filters shall be cleanable or replaceable type and shall entrap
and remove water from oil as recommended by the engine
manufacturer.
B. Day Tank:
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1. Capacity of the day tank shall be not less than:
a. 50 gallons for generator sets specified from 50 KW to 200 KW.
b. 75 gallons for generator sets specified from 201 KW to 300 KW.
c. 4 hours fuel consumption based on 100% load for generator sets
specified over 300 KW.
2. Shall be welded steel, UL approved.
3. Secure, pipe and connect the tank adequately for maximum protection
from fire hazards, including oil leaks.
4. Incorporate a vent, drain cock, shutoff cocks and gauge glass.
Terminate the vent piping outdoors with mushroom vent cap.
5. Incorporate a float switch on the day tank to control the fuel oil
transfer pump and to actuate an alarm in the engine generator control
cubicle when the oil level in the tank drops below the level at which
the transfer pump should start to refill the tank.
a. The float switch contacts, which control the fuel oil transfer
pump, shall be set to energize the pump when the liquid level in
the tank reaches 1/3 of the total volume of the tank.
b. The float switch contacts, which actuate the low fuel oil day tank
alarm device, shall be set to alarm and energize the second fuel
transfer pump when the liquid level in the tank reaches 1/4 of the
total volume of the tank.
6. Day tank and engine supply line elevations shall be below the
elevation of the injector return outlet on the engine.
SPEC WRITER NOTES: In the following
paragraph delete the items enclosed by
//_____// where the radiator will not be
more than 10 feet above the engine.
2.6 ENGINE COOLING SYSTEM
A. Liquid-cooled, closed loop, with // radiator mounted on the engine
generator set // remote radiator // and integral engine driven
circulating pump // as shown on the drawings.
B. Cooling capacity shall not be less than the cooling requirements of the
engine-generator set and its lubricating oil while operating
continuously at 110 percent of its specified rating.
//C.
Water circulating pumps shall be the centrifugal type driven by
engine. Incorporate pressure relief devices, where required, to prevent
excessive pressure increase after the engine stops. //
D. Coolant shall be extended life antifreeze solution, 50 percent ethylene
and 50 percent soft water, with corrosion inhibitor additive as
recommended by the manufacturer
ENGINE GENERATORS
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D. BMEP for the diesel engine, while the engine-generator set is delivering
100 percent of its specified output, shall not exceed the following
maximum limits:
SPEC WRITER NOTES: Designer shall provide
generator set BMEP.
E. The minimum cubic inch displacement of the engine shall not be less than
the value calculated from the following equation:
Displacement
= BHP_x_K_
BMEP x RPM
Where BHP
= Specified KW + R
0.746 x G
K = 396,000 for 2-cycle engines
K = 792,000 for 4-cycle engines
BMEP = Values specified above
RPM = 1800
G = generator efficiency expressed as a decimal
R = horsepower of radiator fan
R = O, when electric motor driven radiator fan is herein
specified
F. The engine shall be able to start in a 4.5 degrees C (40 degrees F)
ambient temperature while using No. 2 diesel fuel oil without the use of
starting aids such as glow plugs and ether injections.
SPEC WRITER NOTES: In the following
subparagraph, insert 0.44 for fuel oil
consumption for generator sets rated less
than 500 KW and 0.40 for sets rated 500
KW, or more.
G. Fuel oil consumption of the engine rate shall not exceed _________
pounds of fuel oil per BHP per hour when it delivers 100 percent of its
specified KW/KVA rating.
H. Equipped with electric heaters for maintaining the engine’s coolant
temperature in the range of 32-38 degrees C (90-100 degrees F) as
recommended by the manufacturer.
1. Install thermostatic controls, contactors, and circuit breaker
protected circuits for the heaters.
2. The heaters shall operate continuously except while the engine is
operating or the water temperature is at the predetermined level.
2.3 GOVERNOR
SPEC WRITER NOTES: Delete hydraulic type
governor when generator set is used in
ENGINE GENERATORS
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paralleling operations and when supplying
a UPS system.
A. Isochronous; electronic or hydraulic type.
B. Steady-state speed band at 60 Hz shall not exceed plus or minus 1/3 of
one percent.
C. At 60 Hz, when load changes equal to 25 percent of the specified KW/KVA
rating, frequency change shall not exceed two percent and it shall
recover to 60 Hz within three seconds.
D. At 60 Hz, when load changes equal to 100 percent of the specified KW/KVA
rating, frequency change shall not exceed eight percent and it shall
recover to 60 Hz within five seconds.
E. While the engine is running, manual speed adjustments may be made.
2.4 LUBRICATION OIL SYSTEM
A. Pressurized type.
B. Positive-displacement pump driven by engine crankshaft.
C. Full-flow strainer and full-flow or by-pass filters.
D. Filters shall be cleanable or replaceable type and shall remove
particles as small as 3 microns without removing the additives in the
oil. For by-pass filters, flow shall be diverted without flow
interruption.
E. Extend lube oil sump drain line passing out through the skid base and
terminate it with a drain valve and plug.
//F.
Provide a 120-volt oil heater for exterior generator set//.
2.5 FUEL OIL SYSTEM
A. Shall comply with NFPA 37 and NFPA 30, and have the following features:
1. Injection pump(s) and nozzles.
2. Plungers shall be carefully lapped for precision fit and shall not
require any packing.
3. Filters or screens, which require cleaning or replacement, will not
be permitted in the injection system assemblies.
4. Return surplus oil from the injectors to the main storage tank by
gravity or a pump.
5. Filter System:
a. Dual primary filters shall be located in the day tank.
b. Secondary filters (engine mounted) shall be located so the oil
will be thoroughly filtered before it reaches the injection system
assemblies.
c. Filters shall be cleanable or replaceable type and shall entrap
and remove water from oil as recommended by the engine
manufacturer.
B. Day Tank:
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26 32 13 - 10
05-10
1. Capacity of the day tank shall be not less than:
a. 50 gallons for generator sets specified from 50 KW to 200 KW.
b. 75 gallons for generator sets specified from 201 KW to 300 KW.
c. 4 hours fuel consumption based on 100% load for generator sets
specified over 300 KW.
2. Shall be welded steel, UL approved.
3. Secure, pipe and connect the tank adequately for maximum protection
from fire hazards, including oil leaks.
4. Incorporate a vent, drain cock, shutoff cocks and gauge glass.
Terminate the vent piping outdoors with mushroom vent cap.
5. Incorporate a float switch on the day tank to control the fuel oil
transfer pump and to actuate an alarm in the engine generator control
cubicle when the oil level in the tank drops below the level at which
the transfer pump should start to refill the tank.
a. The float switch contacts, which control the fuel oil transfer
pump, shall be set to energize the pump when the liquid level in
the tank reaches 1/3 of the total volume of the tank.
b. The float switch contacts, which actuate the low fuel oil day tank
alarm device, shall be set to alarm and energize the second fuel
transfer pump when the liquid level in the tank reaches 1/4 of the
total volume of the tank.
6. Day tank and engine supply line elevations shall be below the
elevation of the injector return outlet on the engine.
SPEC WRITER NOTES: In the following
paragraph delete the items enclosed by
//_____// where the radiator will not be
more than 10 feet above the engine.
2.6 ENGINE COOLING SYSTEM
A. Liquid-cooled, closed loop, with // radiator mounted on the engine
generator set // remote radiator // and integral engine driven
circulating pump // as shown on the drawings.
B. Cooling capacity shall not be less than the cooling requirements of the
engine-generator set and its lubricating oil while operating
continuously at 110 percent of its specified rating.
//C.
Water circulating pumps shall be the centrifugal type driven by
engine. Incorporate pressure relief devices, where required, to prevent
excessive pressure increase after the engine stops. //
D. Coolant shall be extended life antifreeze solution, 50 percent ethylene
and 50 percent soft water, with corrosion inhibitor additive as
recommended by the manufacturer
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E. Radiator core tubes material shall be as recommended by the engine
manufacturer.
F. Fan shall be driven by // multiple belts from engine shaft // totally
enclosed electric motor //.
SPEC WRITER NOTES: Delete the following
paragraph if remote radiator is not used.
If it is used, make sure its motor is
connected ahead of emergency panel circuit
protection.
//G.
Remote Radiator Enclosures:
1. Shall be rugged, tamperproof assemblies framed with steel channels,
angles and braces. Provide fan shroud and fixed louvers and bird
screens at both air intake and exhaust.
2. Shall be securely bolted together to facilitate future dismantling.
Carriage type bolts shall be used with the washers and locknuts on
the inside of the enclosures.
3. Door shall be leveled sheet steel attached with concealed or
semi-concealed hinges. Include a stop edge around the inside of the
door opening and a metal rod stop for 90 degree opening.
4. Anchor the enclosures to concrete bases with bolts, not less than 15mm (1/2-inch) diameter.
5. Radiator fan motor shall be totally enclosed with guarded V-belt
drive and an adjustable mounting base.
6. Coolant piping shall be copper tubing as recommended by the
manufacturer.//
H. Coolant hoses shall be flexible per manufacturer's recommendation.
I. Self-contained thermostatic-control valve shall modulate coolant flow to
maintain optimum constant coolant temperature as recommended by the
engine manufacturer.
SPEC WRITER NOTES: Coordinate motor
operated dampers provided in Division 23
with the engine generator set.
J. Motor-Operated Dampers:
1. Dampers, which are provided under Section 23 31 00, HVAC DUCTS AND
CASINGS, shall be two-position, electric motor-operated.
2. Dampers shall open simultaneously with the starting of the diesel
engine and shall close simultaneously with the stopping of the
engine.
2.7 AIR INTAKE AND EXHAUST SYSTEMS
SPEC WRITER NOTES: Coordinate fresh air
intake location with architectural
drawings and make sure the air intake is
ENGINE GENERATORS
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located away from any exhaust gases to
avoid cross contamination.
A. Air Intake:
1. Provide an engine-mounted air cleaner with replaceable dry filter and
dirty filter indicator.
B. Exhaust System:
SPEC WRITER NOTES: Include the following
paragraph only when the drawings show such
an arrangement. Make sure the exhaust
gases leaving the generator are diffused
properly into the air stream.
//1.
Where turbo-charges are required, they shall be engine-mounted,
driven by the engine gases, securely braced against vibration and
adequately lubricated by the engine's filtered lubrication system //.
2. Exhaust Muffler:
a. Shall be Critical grade type and capable of the following noise
attenuation:
Octave Band Hertz
(Mid Frequency)
Minimum db Attenuation
(.0002 Microbar Reference)
31
5
63
10
125
27
500
37
1000
31
2000
26
4000
25
8000
26
3. Pressure drop in the complete exhaust system shall be small enough
for satisfactory operation of the engine-generator set while it is
delivering 110 percent of its specified rating.
4. Exhaust pipe size, from the engine to the muffler, shall be as
recommended by the engine manufacturer. Pipe size from muffler to air
discharge shall be two-pipe sizes larger than engine exhaust pipe.
5. Connections at the engine exhaust outlet shall be made with a
flexible exhaust pipe. Provide bolted type pipe flanges welded to
each end of the flexible section.
C. Condensate drain at muffler shall be made with schedule 40 black steel
pipe through a petcock.
D. Exhaust Piping and Supports: Black steel pipe, ASTM A-53 standard weight
with welded fittings. Spring type hangers, as specified in Section 23 05
ENGINE GENERATORS
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D. Balance:
1. The vibration velocity in the horizontal, vertical, and axial
directions shall not exceed 16.25 mm (0.65 inch) per second peak at
any specific frequency. These limits apply to main structural
components such as the engine block and the generator frame at the
bearings.
2. Balance the engine-generator set statically and dynamically at the
factory in order to comply with the maximum specified vibration
velocity.
E. Exhaust System Insulation:
1. Adhesive and insulation materials shall be applied on clean, dry
surfaces from which loose scale, and construction debris has been
removed by wire brushing.
2. Fill all cracks, voids and joints of applied insulation material with
high temperature 1093 degrees C (2000 degrees F) insulating cement
before applying the outer covering.
3. The installation shall be neat, thermally and structurally tight
without sag, neatly finished at all hangers or other penetrations and
shall provide a smooth finish surface.
4. Insulation and jacket shall terminate hard and tight at all anchor
points.
5. Insulate completely from engine exhaust flexible connection through
roof or wall construction, including muffler.
3.2 START UP AND TESTING
A. Provide the services of a factory-authorized, factory-trained
representative of the diesel engine-generator set manufacturer to
inspect field-assembled components, and equipment installation and
supervise the field tests
B. When the complete auxiliary electrical power system has been installed
and prior to the final inspection, tests all components of the system in
the presence of the RESIDENT ENGINEER/COTR for proper operation of the
individual components and the complete system and to eliminate
electrical and mechanical defects.
C. Furnish fuel oil, lubricating oil, anti-freeze liquid, water treatment
and rust inhibitor and load bank for testing of the diesel
engine-generator set.
D. Field Tests for the Diesel Engine-Generator Set:
1. Test the engine generator set for eight hours of continuous operation
as follows:
a. First six hours while the set is delivering 100 percent of its
specified KW rating.
ENGINE GENERATORS
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1. The charger shall maintain one percent voltage regulation from no
load to full load for line voltage variation of 10 percent and
frequency variation of ± 3 Hz from 60 Hz.
2. The charger shall maintain a nominal float voltage of 1.4 vdc and a
nominal equalizing voltage of 1.6 vdc.
3. The charger shall be capable of continuous operation in an ambient
temperature of –20 to 60 degrees C (-30 to 104 degrees F) without
derating. The charger shall be convection cooled and housed in a NEMA
250, Type 1 enclosure. The charger shall have a hinged front door and
all components shall be accessible from the front.
4. Provide both AC and DC transient protection. Charger shall be able to
recharge a fully discharged battery without tripping AC protective
devices. AC circuit breaker shall not trip under any DC load
condition including short circuit on output terminals.
5. The charger shall be capable of recharging the fully discharged
battery in 12 hours and simultaneously power the Supervisory and
Control panel.
6. The charger shall have fused AC input and DC output protection, and
shall not discharge the batteries when AC power fails.
7. The charger shall have the following accessories:
a. On-Off control switch with pilot light.
b. Hand adjustable 0 to 24 hour equalize charge timer.
c. AC power failure alarm light.
d. High DC voltage alarm light.
e. DC voltmeter – 5 percent accuracy.
f. DC Ammeter – 5 percent accuracy.
2.9 GENERATOR
A. Synchronous, amortisseur windings, bracket-bearing, self-venting,
rotating-field type connected directly to the engine.
B. Lifting lugs designed for convenient connection to and removal from the
engine at the construction site.
C. Integral poles and spider, or individual poles dove-tailed to the
spider.
D. Insulation shall be as required for the ambient temperature and other
requirements designated in the paragraph, DIESEL ENGINE-GENERATOR SET,
in this section.
E. Designed for sustained short circuit currents in conformance with NEMA
Standards.
F. Designed for sustained operation at 125 percent of the RPM specified for
the generator set without damage.
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G. Telephone influence factor shall conform to NEMA Standards.
H. Furnished with brushless excitation system or static-exciter-regulator
assembly.
I. Nameplates attached to the generator and exciter shall show the
manufacturer's name, equipment identification, serial number, voltage
ratings, field current ratings, KW/KVA output ratings, power factor
rating, time rating, temperature rise ratings, RPM ratings, full load
current rating, number of phases and frequency, and date of manufacture.
J. At full load, the efficiency shall be not less than:
1. 89 percent for sets specified from 60 KW to 175 KW.
2. 92 percent for sets specified over 175 KW.
K. The neutral shall be electrically isolated from equipment ground and
terminated in same junction box as the phase conductors.
SPEC WRITER NOTES:
1. Include reference to "Master Control
Cubicle" when paralleling of generator
sets is involved.
2. Include reference to "Remote
Annunciator Panel" when shown on the
drawings. It is usually to be located at
the Boiler Plant or Engineering Control
Center.
3. Include reference to "Remote
Derangement Panel" when shown on the
drawings. It is usually to be located at a
guard station or nearby nurses' station.
4. Include reference to "Remote Monitoring
Panel" when shown on the drawings. It is
usually to be located at the Engineering
Control Center.
5. Include reference to "Exercising
Control Panel" when multiple transfer
switches are remote from Generator Room.
2.10 EQUIPMENT FOR CONTROLS, SUPERVISION AND DISTRIBUTION
A. Shall include Remote Annunciator Panel.
1. Control Equipment shall be in accordance with UL 508, NEMA ICS-4,
ICS-6 and ANSI C37.90.1.
2. Wiring: Insulated, rated at 600 volts, UL approved.
a. Install the wiring in vertical and horizontal runs, neatly
harnessed.
b. Terminate all external wiring at heavy duty, pressure type,
terminal blocks.
3. Clearly and permanently label the equipment, wiring terminals and
wires.
4. Laminate or mount under plexiglas appropriate wiring diagrams and
mount them within the frame on the inside of the cubicles and panels.
SPEC WRITER NOTES:
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1. When paralleling of diesel generator
sets is not involved, delete last sentence
in paragraph "11" and entire paragraph
"12" below.
2. In the following paragraph insert the
number of generator sets to operate in
parallel.
5. The system shall be designed and manufactured employing the most
modern technology to insure maximum reliability and longevity. It
shall be arranged for automatic and manual starting, and stopping,
//and paralleling of up to //______// diesel generator sets //.
6. All indicating lamps and switches shall be accessible and mounted on
the cubicle doors.
SPEC WRITER NOTES:
1. Include paragraph entitled "Remote
Annunciator Panel" when shown on the
drawings.
2. In Article 2.13, paragraphs B.1a and b,
change the word "Which" to "When" if
paralleling of sets is not involved.
2.11 REMOTE ANNUNCIATOR PANEL
A. Remote annunciator panel shall be installed at the location shown on the
drawings.
B. The annunciator shall indicate alarm conditions of the emergency or
auxiliary power source as follows:
1. Individual visual signals shall indicate:
a. Which generator is operating to supply power to load.
b. Which battery charger is malfunctioning.
c. When main storage tank is low.
2. Individual visual signals plus a common audible alarm shall warn of
the following:
a. "Low lubricating oil pressure - FIRST STAGE."
b. "Low coolant."
c. "Excessive coolant temperature - FIRST STAGE."
d. Low fuel - day tank."
e. "Overcrank" (failure to start).
f. "Overspeed."
C. The annunciator shall also have the following features:
1. One pushbutton momentary contact switch. Label switch "LAMP - TEST".
Initiating this switch shall momentarily actuate the alarm buzzer and
all the indicating lamps.
2. Audible Alarm: There shall be an audible alarm, rated for 85 dB at 10
feet, which shall become actuated whenever an alarm condition occurs.
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A momentary-contact acknowledge pushbutton shall silence the audible
alarm, but not clear the alarm lamp. Elimination of the alarm
condition shall automatically release the seal-in circuit for the
audible alarm and extinguish the alarm lamp //.
SPEC WRITER NOTES: When a derangement
panel is required, insert the following
paragraph.
2.12 SOUND ATTENUATED ENCLOSURE
A. The emergency generator set and related equipment shall be housed in an
outdoor weatherproof enclosure. The generator will function properly
without overheating in the ambient conditions specified. // Enclosure
shall be weatherproof and sound attenuated (maximum 85 dBA at 1525 mm
(five feet) from any side, top and bottom to no more than 75 dBA when
measured at 15 meters (50 feet) horizontally from any part of the
enclosure) //Enclosure shall be walk-in type and sound attenuated
(maximum 85 dBA at 1525 mm (five feet) from any side, top and bottom to
no more than 75 dBA when measured at 15 meters (50 feet) horizontally
from any part of the enclosure or appendage on the enclosure.)// Sound
ratings shall be based on full load condition of engine/generator in a
single unit operation condition. Airflow configuration of the unit will
be intake through rear of unit and discharge air vertically up.
Enclosure shall be suitable for winds up to 193 kmh (120 mph); roof load
shall be equal to or greater than 200 kg/sq m (40 lbs per sq. ft). Nondistributed loading as required.
B. The enclosure shall meet the following requirements:
1. The exterior finish shall be guaranteed for a period of 10 years to
be free from any defects when properly maintained.
//2.
Enclosure shall be of sufficient size allowing for code clearances
and proper servicing isles without removal or opening of enclosure
panels.//
3. Radiator exhaust outlet shall be ducted through the end of the
enclosure.
4. All exterior surfaces shall be factory painted with industrial
enamel.
5. Unit shall have sufficient guards to prevent entrance by small
animals.
6. Batteries to fit inside enclosure and along side the engine provide
protective shield. (Batteries under the generator are not
acceptable.)
7. Exhaust System: The silencer shall be critical grade, mounted and
thermally insulated inside the enclosure. Insulation must be provided
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for the silencer, flex and all discharge piping. The weight of the
silencer shall not be supported by engine. The exhaust pipe size
shall be sufficient to insure that exhaust backpressure does not
exceed the maximum limitations specified by the engine manufacturer.
The exhaust silencer outlet roof penetration shall be sealed to
prevent the entrance of rain, snow and sleet. A stainless steel
bellowed flex shall be provided.
2.13 SPARE PARTS
A. For each engine-generator set:
1. Six lubricating oil filters.
2. Six primary fuel oil filters.
3. Six secondary fuel oil filters.
4. Six intake air filters.
B. For each battery charger:
1. Three complete sets of fuses.
2. One complete set of indicating lamps.
C. For each control and supervisory panel:
1. Three complete sets of fuses.
2. One complete set of indicating lamps.
PART 3 - EXECUTION
3.1 INSTALLATION
A. Install concrete bases of dimensions shown on the drawings for packaged
engine-generator sets.
B. Installation of the engine generator set shall comply with
manufacturer's written instructions and with NFPA 110.
C. Mounting
1. Support the base of engine-generator set on vibration isolators, each
isolator bolted to the floor (pad), generator base bolted to
isolator.
2. Install sufficient number of isolators so that the floor (pad)
bearing pressure under each isolator is within the floor (pad)
loading specification.
3. Install equal number of isolators on each side of the
engine-generator set's base.
4. Locate isolators for approximately equal load distribution and
deflection per isolator. Base of the engine-generator set shall be
drilled at the factory for the isolator bolts.
5. Isolators shall be shipped loose with the engine-generator set.
6. All connections between the engine-generator set and exterior
systems, such as fuel lines, electrical connections, and engine
exhaust system and air exhaust shroud, shall be flexible.
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D. Balance:
1. The vibration velocity in the horizontal, vertical, and axial
directions shall not exceed 16.25 mm (0.65 inch) per second peak at
any specific frequency. These limits apply to main structural
components such as the engine block and the generator frame at the
bearings.
2. Balance the engine-generator set statically and dynamically at the
factory in order to comply with the maximum specified vibration
velocity.
E. Exhaust System Insulation:
1. Adhesive and insulation materials shall be applied on clean, dry
surfaces from which loose scale, and construction debris has been
removed by wire brushing.
2. Fill all cracks, voids and joints of applied insulation material with
high temperature 1093 degrees C (2000 degrees F) insulating cement
before applying the outer covering.
3. The installation shall be neat, thermally and structurally tight
without sag, neatly finished at all hangers or other penetrations and
shall provide a smooth finish surface.
4. Insulation and jacket shall terminate hard and tight at all anchor
points.
5. Insulate completely from engine exhaust flexible connection through
roof or wall construction, including muffler.
3.2 START UP AND TESTING
A. Provide the services of a factory-authorized, factory-trained
representative of the diesel engine-generator set manufacturer to
inspect field-assembled components, and equipment installation and
supervise the field tests
B. When the complete auxiliary electrical power system has been installed
and prior to the final inspection, tests all components of the system in
the presence of the RESIDENT ENGINEER/COTR for proper operation of the
individual components and the complete system and to eliminate
electrical and mechanical defects.
C. Furnish fuel oil, lubricating oil, anti-freeze liquid, water treatment
and rust inhibitor and load bank for testing of the diesel
engine-generator set.
D. Field Tests for the Diesel Engine-Generator Set:
1. Test the engine generator set for eight hours of continuous operation
as follows:
a. First six hours while the set is delivering 100 percent of its
specified KW rating.
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b. Last two hours while the set is delivering 110 percent of its
specified KW rating.
c. If during the 8-hour continuous test a failure occurs, either the
diesel engine shuts down or the full KW rating of the load bank is
not achieved, the test is null and void. The test(s) shall be
repeated until the satisfactory results are attained at no
additional cost to the government.
2. Record the following test data at 30-minute intervals:
a. Time of day, also reading of running time indicator.
b. KW.
c. Voltage on each phase.
d. Amperes on each phase.
e. Engine RPM.
f. Frequency.
g. Engine water temperature.
h. Fuel pressure
i. Oil pressure.
j. Outdoor temperature
k. Average ambient temperature in the vicinity of the diesel engine.
l. Average ambient temperature in the vicinity of the starting
batteries.
3. Demonstrate that the generator set will attain proper voltage,
frequency and will accept 100 percent block load within 10 seconds
from a cold start after the closing of a single contact.
4. Furnish a resistance type load for the testing of the generator:
a. When approved in writing by the RESIDENT ENGINEER/COTR prior to
the testing, the Contractor may use connected loads in the
building (resistant plus other types) as part of the test load
provided the Contractor assumes complete responsibility for the
use of the connected loads, including personnel injuries and
property damage.
b. Test loads shall always include adequate resistance to assure
stability of the loads and equipment during all of the testing
operations. The test load KW rating:
1) Shall not be less than 110 percent of the specified KW rating
of the largest generator set.
2) Shall not be less than 35 percent of the sum of the specified
KW ratings of the all generator sets in a paralleling system.
E. Battery and Starting System Test:
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1. Demonstrate that the batteries and cranking motor are capable of 5
starting attempts of 10 second cranking each at 10 second intervals
with the battery charger turned off.
F. Test local and remote panels: Simulate engine failures while checking
for proper operation of each indicating lamp, alarm device and reset
button. (It is recommended that one VA inspector be located in the
generator room and another at the site of remote panels. By means of
telephone or walkie-talkies, the inspectors should be assured of proper
operation and coordination of these panels.)
G. At the completion of the field tests, fill the underground storage tank
with fuel of grade and quality as recommended by the manufacturer of the
engine.
H. When any defects are detected during the tests, correct all the
deficiencies and repeat all or part of the 8-hour continuous test as
requested by the RESIDENT ENGINEER/COTR, at no additional cost to the
Government.
I. Provide test and inspection results in writing to the RESIDENT
ENGINEER/COTR.
3.3 INSTRUCTIONS AND FINAL INSPECTIONS
A. Laminate or mount under Plexiglas a set of operating instructions for
the system and install instructions within a frame mounted on the wall
near the diesel engine-generator set as requested by the RESIDENT
ENGINEER/COTR.
B. At the final inspection in the presence of a VA representative,
demonstrate that the complete auxiliary electrical power system operates
properly in every respect.
C. Furnish the services of a competent, factory-trained engineer or
technician for five, 4-hour periods for instructions to VA personnel in
operation and maintenance of the equipment, on the dates requested by
the RESIDENT ENGINEER/COTR.
- - - END - - -
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